Industrial-Grade Liquid Cooled Load Bank Application Cases: Testing Scheme Practice in New Energy and Energy Storage Fields

30kW liquid cooled load bank
 

In the field of new energy vehicle charging pile testing, a charging pile manufacturer faced the problem of performance verification for high-power fast-charging piles (200kW and above): when the traditional load bank conducted full-power testing, the temperature rose sharply due to untimely heat dissipation, which not only led to high test interruption frequency but also easily caused aging of internal components of the equipment. To this end, the enterprise introduced an industrial-grade liquid cooled load bank to build a testing system: first, according to the power range of fast-charging piles, a liquid cooled load bank with a load adjustment range of 0-300kW was selected to ensure coverage of testing needs for different types of charging piles; second, the efficient heat dissipation capacity of the liquid cooling system was used to stably control the equipment operating temperature at 35±2℃, avoiding the impact of high temperature on the accuracy of test data; at the same time, through the dynamic load simulation function of the load bank, the real load changes of the charging pile in different charging stages (such as constant current and constant voltage stages) were simulated to verify the output stability and overload protection performance of the charging pile. Practice shows that this scheme increased the testing efficiency by 40%, controlled the test data deviation within ±1%, and successfully helped the enterprise pass the charging pile industry certification.​

In the energy storage field, a large-scale energy storage power station needed to conduct charge-discharge cycle testing and emergency working condition verification on the lithium battery energy storage system to ensure the safe grid-connected operation of the power station. The previously used resistive load bank had problems of high energy consumption and poor temperature control accuracy. The power consumption of a single test was equivalent to the monthly average electricity consumption of 50 households, and it could not simulate extreme load fluctuation scenarios. After introducing the industrial-grade liquid cooled load bank, the testing scheme achieved three major optimizations: first, through the energy recovery module of the liquid cooled load bank, the electrical energy generated during the testing process was converted into thermal energy for recycling, reducing the energy consumption of a single test by 65% and saving more than 200,000 yuan in electricity bills annually; second, for the "charge-discharge switching" working condition of the energy storage system, the load bank could complete load adjustment within 0.5 seconds, simulating load fluctuations when the power grid suddenly failed, and verifying the response speed and power supply stability of the energy storage system; third, combined with the remote monitoring platform, real-time data such as load current and temperature were collected to generate multi-dimensional test reports, providing data support for the optimization of the energy storage system. This scheme not only met the testing needs of the energy storage power station but also realized the green and low-carbon operation of the testing process.​

From the performance verification of new energy charging piles to the safety testing of energy storage power stations, industrial-grade liquid cooled load banks have solved the high-power and high-stability testing problems for the two fields through customized testing schemes. In the future, as the power of new energy and energy storage equipment continues to increase, liquid cooled load banks will play a role in more segmented scenarios, providing reliable testing guarantees for the high-quality development of the industry.